Real-time quality monitoring of beverage batch production using densitometry

ABSTRACT

Aspects of the disclosure include a method for producing a batch according to a batch process that includes adding ingredients to water to form a batch, mixing the batch, measuring the drive gain of the batch in real time using an in-line density device, monitoring amplitude variation of the drive gain, comparing the amplitude variation of the drive gain to a predetermined threshold, and providing an indication based on the amplitude variation of the drive gain that the batch is homogeneously dispersed or fully dissolved. Other aspects of the disclosure relate to a method for detecting homogeneity of a mixture and a method of determining the degree of mixing of a batch.

CROSS-REFERENCE

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/793,398, filed Oct. 25, 2017, which is herein incorporatedin its entirety by reference thereto.

BACKGROUND Field of the Invention

The described embodiments relate generally to a batch process forproducing a beverage, including measuring characteristics of the batchprocess in real time.

BRIEF SUMMARY

Aspects of the disclosure include a method for tracking the quality of abeverage produced according to a batch process. The batch process mayinclude adding ingredients to water to form a batch. A first ingredientmay be added, then the batch may be mixed until the first ingredient isfully mixed, then a second ingredient may be added, and the batch may bemixed until the second ingredient is fully mixed. Additionally, themethod may include measuring the density of the batch in real time usingan in-line density device, monitoring changes in density of the batch,detecting deviations from the batch process based on the changes indensity, and correcting for any detected deviations from the batchprocess in real time. The method may also include comparing the densitymeasurements to a standard beverage recipe and matching the densitymeasurements to the standard beverage recipe.

In other aspects of the disclosure, a method of detectinginhomogeneities in a batch process for producing a beverage may includemixing ingredients to form a batch, measuring drive gain of the batch inreal time, monitoring changes in the drive gain, detecting inhomogeneityin the batch based on the changes in the drive gain, and correcting forany detected inhomogeneity from the batch process in real time.

In other aspects of the disclosure, a method of tracking addition ofingredients for producing a beverage in a batch process may includesequentially adding ingredients to water according to a recipe to form abatch, measuring the density of the batch in real time using an in-linedensity device, monitoring changes in density of the batch after eachingredient is added to the batch, detecting deviations from the standardrecipe, and correcting for any detected deviations from the batchprocess in real time.

In other aspects of the disclosure, a method of producing a batch usinga batch process may include adding a first ingredient to water to form abatch, mixing the batch, measuring a drive gain amplitude of the batchusing an in-line density device, monitoring drive gain amplitudevariation, comparing the drive gain amplitude variation to apredetermined threshold, providing an indication based on the variationin drive gain amplitude that the batch is homogeneously dispersed orfully dissolved, and mixing the batch until the indication is provided.

In other aspects of the disclosure, a method for detecting homogeneitiesof a mixture may include adding an ingredient to water to form themixture, measuring drive gain amplitude of the mixture using an in-linedensity device, monitoring variation in the drive gain amplitude,comparing the variation in the drive gain amplitude to a predeterminedthreshold, and determining, based on the comparing step, whether themixture is fully dissolved or homogeneously dissolved.

In other aspects of the disclosure, a method of determining the degreeof mixing of a batch includes adding a first ingredient to water to forma batch, adding a second ingredient to the batch, mixing the batch,measuring the drive gain amplitude of the batch in real time using anin-line density device, monitoring variation in the drive gainamplitude, comparing the variation to a first standard referencecorresponding to a homogeneously dissolved mixture and a second standardreference corresponding to a fully dissolved mixture, and providing anindication of the degree of mixing based on the comparing step.

BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES

FIG. 1 shows an exemplary beverage-creation batch process system with anin-line density device attached to a recirculation loop.

FIG. 2A shows the exemplary in-line density device.

FIG. 2B shows a bottom-up view of the in-line density device of FIG. 2A.

FIG. 2C shows a bottom-up view of the in-line density device of FIG. 2Athat is oscillating due to fluid flowing through the device.

FIG. 3 shows an exemplary graph produced based on readings from thein-line density device.

FIG. 4A shows a cross-section of a tube with a single phase of fluidflowing through the tube.

FIG. 4B shows a cross-section of a tube with two phases flowing throughthe tube.

FIG. 5 shows a chart of decoupling ratio versus density ratio of anexemplary batch.

FIG. 6 shows density and drive gain measurements over time for anotherexemplary batch.

FIG. 7 shows density and drive gain measurements over time for anotherexemplary batch.

FIG. 8 shows more detailed density and drive gain measurements foranother specific time range for the batch shown in FIG. 7.

FIG. 9 shows a side-by-side comparison of the density of the batch shownin FIG. 6 to the density of the batch shown in FIG. 7.

FIG. 10 shows a comparison of density measurements completed by thein-line density device to an offline density device.

FIG. 11 shows data points that represent the difference in measurementsbetween the in-line density device and the offline density device.

FIG. 12 shows data points that represent the confidence intervals ofdata related to drive gain amplitude variation for various samples.

FIG. 13 shows box plots with data related to drive gain of varioussamples.

DETAILED DESCRIPTION

Many pre-packaged beverages are made industrially using batch processesthat follow complex recipes. For example, a recipe may provideinstructions to add multiple ingredients into a big vat of water, oneafter another in varying amounts, and to ensure that each ingredient isfully mixed or that enough time has passed before adding anotheringredient. These recipes often require a large number of ingredients,including liquids with different viscosities or solids (e.g., powders),each of which may dissolve at a different rate. Often these ingredientsare added manually by operators who visually determine whether theingredient is fully mixed. Oftentimes, the beverage formulas or recipesare very complex and include hard-to-dissolve solids. This makes itespecially challenging to monitor product quality in-line.

Relying on manual addition of ingredients and visual inspection ofmixtures leaves room for potential errors in the batch process. Forexample, an operator may add the wrong amount of an ingredient, leave aningredient out of the batch entirely, or prematurely move on or completethe batch before an ingredient is fully mixed. It is difficult to trackand quantify the amount of ingredients added and the quality of mixingwhile the ingredients are being mixed. It is also difficult to determinewhether the ingredients are not dissolved, homogeneously dispersed, orfully dissolved. Thus, an analysis of the batch is often necessary aftercompletion of the process, to ensure it meets standards.

Once the batch has been completed, however, it can be costly, andsometimes impossible, to correct any errors, and in some cases theentire batch must be discarded. This results in wasted time, money, andmaterials. In addition to these potential operator errors, eachindividual beverage-making facility may use different equipment andinputs of varying quality sourced from different suppliers, potentiallyresulting in varying batch quality, or the need for facility-specificquality-control measures. Thus, in-line analysis of the batch can behelpful in measuring and tracking ingredients added during a batchprocess and in promoting consistent batch quality among variousmanufacturing facilities. In-line analysis can also be helpful indetermining whether the ingredients of a batch are not dissolved,homogeneously dispersed, or fully dissolved.

An in-line density device may be used to monitor batch characteristicsin real time, so that errors can be corrected in real time, or avoidedaltogether. In-line density devices, which may include components suchas a flowmeter and a densitometer, can be used to continuously measuredensity, flow rate, and other characteristics to deduce ingredientconcentrations in the batch. Unlike existing analysis methods that useoff-line analysis of the batch, in-line density devices may be used tocontinuously monitor and quantify the batch as ingredients are added.The device and method may also be used to identify batch characteristicsthat can be used to determine a specific standard that is unique to eachbeverage recipe. By continuously measuring characteristics of the batch,the in-line density device can aid in evaluating the batch against theideal “gold standard” batch (e.g., a target recipe”) characteristics andmaking adjustments in real-time to avoid issues such as incompletemixing, inconsistent batch quality, and other problems.

FIG. 1 shows an exemplary batch system 50 for producing a beverage.Batch system 50 may include a mixing tank 55, an ingredient inlet 60, anoutlet 70, a batch 80, and a recirculation loop 90. Ingredients flowinto mixing tank 55 through ingredient inlet 60 in the direction ofarrow 65. Once in mixing tank 55, the ingredients are mixed to formbatch 80, which continuously flows through recirculation loop 90. Asbatch 80 flows through recirculation loop 90, in-line density device 100measures the density and mass flow rate of batch 80. Once batch 80 iscomplete, batch 80 may flow out of mixing tank 55 through outlet 70 inthe direction of arrow 75, to be further processed (e.g., packaged intobottles or other containers).

Ingredients may be manually added to mixing tank 55 through ingredientinlet 60A or by being poured over the top of mixing tank 55 (e.g., inthe direction of arrow 60B). Existing methods monitor batch qualityafter the batch has been mixed in mixing tank 55 and leaves throughoutlet 70. These methods use offline testing with laboratory equipment.These methods cannot measure the batch quality in real time orcontinuously during the batch-creation process. In contrast, usingrecirculation loop 90 and in-line density device 100, the density ofbatch 80 may be measured in real time. As batch 80 is being processed,in-line density device 100 may continuously measure the density of batch80, and the measurements returned can be used to determine the qualityof batch 80, including whether batch 80 conforms to a standard recipeand whether ingredients are fully mixed into batch 80. In-line densitydevice 100 may provide density measurements as precise as the offlinedensity device, or within a small margin of error. In some embodiments,the in-line density device provides measurements that are within a0.001%, 0.005%, 0.01%, 0.02%, 0.05%, 0.1%, 0.5%, 1%, or 5% margin oferror.

FIGS. 2A-2C show an exemplary in-line density device 100. In someembodiments, in-line density device 100 is a Coriolis density meter.FIGS. 2B and 2C show a bottom-up view of in-line density device 100 ofFIG. 2A. In-line density device 100 includes a tube 110 (e.g., part ofrecirculation loop 90), a first flow tube 120, and a second flow tube130. To measure density and mass flow rate using in-line density device100, the batch enters first flow tube 120 and second flow tube 130. Eachof the flow tubes 120 and 130 may have a magnet and coil assembly 115,and as the batch passes through flow tubes 120 and 130, Coriolis forcesmay be induced, which causes flow tubes 120 and 130 to twist inopposition to one another. Coriolis density meters are equipped withsensors that can measure the twisting of flow tubes 120 and 130 anddirectly measure the density and mass flow rate.

FIGS. 2A and 2B show the position of flow tubes 120 and 130 without anyfluid flowing through in-line density device 100. FIG. 2C showsexemplary positions of flow tubes 120 and 130 with fluid flowing throughin-line density device 100. Fluid flows through in-line density device100 in the direction of arrows 105. Flow tubes 120 and 130 bothoscillate as fluid flows through the tube, and the rate at which massflows through the tubes affects the oscillation of the tubes. The magnetand coil assembly creates a voltage in the form of sine waves as fluidflows through tubes 120 and 130. Additionally, a densitometer, such as aCoriolis density meter, registers spikes in density when air bubbles andundispersed powders are present in the system. This is due to changes inthe location of the center of gravity of the fluid inside the tube, alsoknown as “drive gain.” Drive gain shows a small but detectible spikewhen there are two phases (e.g., solid and liquid) present in thesystem.

The response of the drive gain depends on the decoupling of the solidsfrom the liquid. This phenomenon can be used as another indication ofinhomogeneity in a mixture or changes in viscosity or productmicrostructure.

Additionally, the presence of air bubbles and particles in the flow isknown to cause measurement errors, referred to as decoupling ormultiphase error. Decoupling refers to the relative motion between twoingredients of differing density in the direction of the tubeoscillation, which is perpendicular to the direction of the bulk fluidflow.

FIG. 3 illustrates an exemplary output of measurements by in-linedensity device 100. Line 300 shows the density of the batch over time,and line 400 shows the drive gain of the batch over time. As shown inFIG. 3, the density spikes, shown by peaks 301, 302, and 303, and levelsout higher each time an ingredient is added. Similarly, the drive gainspikes, shown by peaks 401, 402, and 403, each time an ingredient isadded. Following the spikes, line 400 shows a reduction in the drivegain back to the value before the ingredient was added. This return tothe lower value indicates the added ingredient has been well-mixed intobatch 80 such that batch 80 is homogenous.

FIG. 4A illustrates a single phase, a first phase 140, flowing throughfirst flow tube 120. FIG. 4B illustrates two phases, first phase 140 anda second phase 142, flowing through first flow tube 120. First phase 140may be liquid (e.g., the homogenous portion of batch 80) and secondphase 142 may be solid (e.g., a newly-introduced ingredient that has notyet been well-mixed into batch 80. It is to be understood that more thantwo phases are possible, and similar flow occurs in second flow tube130. The center of gravity, shown by circle 144, is in the center offirst flow tube 120 when there is one phase present, as in FIG. 4A. Asshown in FIG. 4B, the center of gravity, shown by circle 144, is nolonger in the center of first flow tube 120, which can cause fluid massto appear lighter than it really is. The ratio of A_(p)/A_(f), which isthe ratio of the amplitude of particle oscillation (A_(p)) to theamplitude of fluid oscillation (A_(f)) is the decoupling ratio. Line 152represents A_(f) and line 154 represents A_(p).

FIG. 5 shows decoupling results for various solids. The y-axis isdecoupling ratio (A_(p)/A_(f)), and the x-axis is density ratio (fluiddensity/particle density). A decoupling ratio of 1 indicates that thecenter of gravity of the fluid and the center of gravity of the tube aremoving in sync. Decoupling ratios above and below 1 indicate that aparticle is present that is skewing the centers of mass. Errors indensity measurements are minimized as the decoupling ratio approaches 1.

Batch Quality

Using an in-line density device, such as the one described above, it ispossible to measure and track certain characteristics of a batchprocess, which can enable ready determination of the quality of thebatch. For example, in some embodiments, an “ideal” batch can beproduced in a batch process (i.e., a “target recipe,” a “standardizedprocess,” a “standard beverage recipe,” or a “gold standard”). Duringthe production of the “ideal” batch, the in-line density device cancontinuously track and monitor, in real time, the density and the drivegain of the batch. During the batch process, or following the completionof the batch, the in-line density device can provide target recipe datasuch as that shown in FIGS. 6-10. This target recipe data can provide astandardized reference for reproducing that same “ideal” batch.

Using this standardized process, it is possible to set certainparameters or tolerances for error in the batch (e.g., pass/failcriteria). If the in-line density device detects density levels withinthe parameters or tolerances, then the batch “passes.” If the in-linedensity device detects density levels outside of the parameters ortolerances, then the batch “fails” and the in-line density device mayprovide an alert or notification that the batch has deviated from thestandardized process. For example, in some embodiments, if the in-linedensity device detects density levels that deviate more than 1% from theexpected value, the device may provide an alert. In some embodiments, ifthe in-line density device detects density levels that deviate more than1%, 5%, 10%, or 15%, then the device will provide an alert.

Additionally, in-line density device 100 may be in communication with asoftware that measures the drive gain, measures the density, monitorschanges in the density of the batch in real time, and detects deviationsof the density from a target recipe. The software may also provide analert based on the tolerances discussed above. The software may providethe alert automatically if deviations from the target recipe aredetected. For example, the software may provide an alert if the softwaredetects a deviation of at least 1% from the target recipe. The softwaremay also provide an automatic alert when the drive gain increases,indicating inhomogeneity in the batch, or when the drive gain returns toa steady state or expected value. The software may also be incommunication with a mixer of mixing tank 55 to automatically mix batch80 if an increase in drive gain is detected.

The batch process begins with adding water to mixing tank 55. Water maybe considered the first ingredient in batch 80. Mixing tank 55 may havea capacity of greater than 5 gallons, for example (e.g., greater than30, 90, or 500 gallons as may be used in industrial beverageproduction). After the water is added, the water flows throughrecirculation loop 90 and in-line density device 100, such as adensitometer, measures the density of the water. In some embodiments,in-line density device 100 is a Coriolis density meter. Following themeasurement of the density of the water, ingredients may be added tobatch 80. The ingredients may be liquids, solids, or gases. Batch 80 maycontinuously flow through recirculation loop 90, and in-line densitydevice 100 may continuously measure the density of batch 80. In someembodiments, the ingredients are added sequentially, and the density ismeasured continuously. The inline densitometer reads the densityinstantaneously. The density measurements during ingredient addition aremonitored in real time through graphic display. Subsequent ingredientsmay be added after density fluctuations from previous addition plateauto constant density value. The density may be measured for less than 1second, at least 1 second, at least 30 seconds, at least 1 minute, atleast 2 minutes, at least 3 minutes, at least 4 minutes, or at least 5minutes. The density may also be measured until the output reading fromin-line density device 100 indicates that batch 80 sufficiently matchesthe target recipe data, or until the drive gain reading indicates thatbatch 80 is well-mixed. Additionally, the measured density may becompared continuously to the density of the target recipe data, and anydeviations cause an alert or notification as described above.

Deviations from the target recipe data can also be corrected in realtime. For example, if the density measurements indicate an ingredient ismissing or present in an incorrect amount, more of the ingredient can beadded, the batch can be diluted, or other combinations of ingredientscan be added to bring the batch back within acceptable specifications.For example, if the deviation indicates there is too little of aningredient, additional amounts of the ingredient may be added until thedensity meets the target recipe data. Also for example, if the deviationindicates there is too much of an ingredient, additional water may beadded to the batch, and any other ingredient amounts may be increaseduntil the density meets the target recipe data. The drive gain may bemeasured in real time and continuously, and the process may provide analert or notification to any drive gain readings that indicateinhomogeneity.

Following the addition of each ingredient, the drive gain is alsomeasured (e.g., simultaneously with the density), which determineswhether batch 80 is in a single- or multi-phase. If the drive gainindicates there is inhomogeneity (e.g., batch 80 is in multi-phase),this provides an opportunity to correct for such inhomogeneity in realtime. For example, if the drive gain indicates there are undissolvedsolids, agglomeration, changes in viscosity, or gases present, batch 80may be further mixed until the drive gain returns to a value thatindicates a homogenous or well-mixed mixture. The drive gainmeasurements may also be used to detect changes in the viscosity orproduct microstructure, which may be corrected in real time by, forexample, the addition of further ingredients.

The process may provide certain tolerances for changes in the drive gainand may provide an alert or notification if the changes in the drivegain exceed those tolerances, so that corrective action can be taken aswarranted. In some embodiments, the process will provide an alert if thedrive gain changes more than 1%, 2%, 5%, or 10%. Following such analert, the system may automatically mix the batch until the drive gainis reduced to a level that indicates a homogeneous or well-mixedmixture. For example, the system may measure the drive gain of wateronly as a baseline, before any ingredients have been added, then aftereach ingredient is added it may then mix the batch until the drive gainis reduced to within ±1% of the baseline drive gain of water only.

In some embodiments, the process for measuring density and drive gain ofthe batch process may be used to align various production facilitiesthat use different equipment and inputs of varying quality sourced fromdifferent suppliers, resulting in the potential for varying batchcharacteristics attributable to their varying ingredients, equipment,and processes. By providing an objective quantitative standard againstwhich batch characteristics can be measured in real time, such disparatefacilities can more easily output consistent product. In someembodiments, the process may be used for facility-specificquality-control measures. By creating a standardized recipe or batch asdescribed above, various facilities can use this process to readilydetermine whether subsequent batches meet quality standards.

Degree of Homogeneity or dissolution

In addition to tracking addition of ingredients and monitoring batchquality, the system can also be used to determine whether ingredientsare dispersed or dissolved in a batch or mixture, and to determine thedegree to which ingredients of a batch or mixture are dispersed ordissolved. As discussed above, after an ingredient (e.g., liquid orpowder) has been added to mixing tank 55, in-line density device 100registers a spike in density and drive gain, indicating the addition ofan ingredient. Once the density and drive gain reach a steady state(e.g., at the time between peaks 301 and 302 or between peaks 401 and402 in FIG. 3), the mixture may be considered well-mixed. However,determining that a mixture is well-mixed does not necessarilydifferentiate between ingredients that are fully dissolved within themixture or just homogeneously dispersed throughout the mixture. In someinstances, for optimum batch quality, it can matter whether aningredient is fully dissolved or homogeneously dispersed beforeproceeding with the batch creation process.

Thus, beyond determining that the ingredient is well-mixed within thebatch, there is additionally a benefit to determining whether theingredients in the batch are fully dissolved or homogeneously dispersed.In addition to determining if the batch is homogeneous or well-mixed,the system can determine at a more granular level whether an ingredientis not fully dissolved, is homogeneously dispersed, or is fullydissolved.

Differentiating between a fully dissolved ingredient and a homogeneouslydispersed ingredient can further improve productivity and efficiency ofa batch process. In some embodiments, this allows for a reduced batchcycle time by allowing a more precise determination of required mixingtimes. For example, an additional ingredient can be added immediatelyafter the system indicates that the batch is homogeneously dispersed,avoiding unnecessary delays between addition of various ingredients.Further, this method can improve quality by avoiding premature additionof new ingredients. In some embodiments, a new ingredient may be addedonly after a prior ingredient is homogeneously dispersed throughout thebatch. In some embodiments, a new ingredient may be added only after thesystem indicates that a prior ingredient is fully dissolved within thebatch. Additionally, the methods disclosed herein may allow fordata-driven troubleshooting, which can provide better, faster, and moreconsistent troubleshooting and correction of batch processing problemsthan relying on operator observation and judgment. In some embodiments,the troubleshooting and correction of batch processing problems is donein real-time during batch processing.

As discussed above, the batch may be mixed after each ingredient isadded until the drive gain reaches a reduced level, indicating a fullymixed batch. The drive gain can then optionally be further monitored todetermine whether the batch is fully dissolved or the batch ishomogeneously dispersed. For example, variations in the amplitude of thedrive gain can be monitored and can indicate that the batch is eitherfully dissolved or homogeneously dispersed. In some embodiments, when abatch is fully dissolved, the drive gain amplitude variation andfrequency range will be smaller than when the batch is homogeneouslydispersed.

As discussed above and as illustrated in FIGS. 7 and 8, higher drivegain generally corresponds to increased inhomogeneity in a batch ormixture. Drive gain spikes when there are two phases (e.g., solid andliquid) present in the system. By measuring the drive gain amplitudevariations, it is possible not only to detect inhomogeneity, but also todetect whether the batch or mixture is homogeneously dispersed or fullydissolved.

In some embodiments, the method includes producing a batch by adding afirst ingredient (e.g., a liquid or solid) to water or other liquid toform a batch. The first ingredient may be any beverage ingredient (e.g.,any of the ingredients discussed throughout this disclosure). In someembodiments, the first ingredient is added to water to form the batch.In some embodiments, the first ingredient is added to a mixturecomprising other ingredients. In some embodiments, additionalingredients may be added. For example, a second ingredient, a thirdingredient, a fourth ingredient, or a fifth ingredient may be added. Insome embodiments, one or more ingredients are added before the batch ismixed and drive gain is measured. In some embodiments, ingredients areadded sequentially, and the batch is mixed and drive gain is measuredafter each ingredient is added.

In some embodiments, the batch may flow through an in-line densitometer(e.g., a Coriolis density meter) to measure the drive gain of the batch.In some embodiments in-line density device 100 measures the drive gainof the batch. In some embodiments, the drive gain is measured in realtime. In some embodiments, the drive gain measurements may be used tomonitor amplitude variations of the drive gain of the batch. Theamplitude variations of the drive gain may be monitored continuously orintermittently throughout the batch process. In some embodiments, theamplitude variation of the drive gain is measured continuously. In someembodiments, the amplitude variation of the drive gain is measured inreal time. In some embodiments, the amplitude variation of the drivegain is measured after all ingredients of the batch have been added(e.g., a pre-assembled or a pre-mixed batch) to determine whether thebatch is fully dissolved or the batch requires additional mixing.

In some embodiments, as the amplitude variation of the drive gain ismonitored, the amplitude variation may be compared to a standard value.The standard value may be, for example, a predetermined threshold valueor a standard reference value. The standard value may be equal to avalue indicating that the batch ingredients are not dissolved, a valueindicating that the batch ingredients are homogeneously dispersed, or avalue indicating that the batch ingredients are fully dissolved. In someembodiments, one standard value corresponding to a fully dissolved batchmay be targeted. In some embodiments, two standard values may betargeted: one corresponding to a fully dissolved batch and onecorresponding to a homogeneously dispersed batch. In some embodiments,more than two standard values may be targeted. In some embodiments,these standard values may be used as a point of reference. In someembodiments, the method may include determining whether the amplitudevariation of the drive gain is greater than or less than the standardvalue. For example, amplitude variation greater than the standard valuemay indicate that the batch ingredients are homogeneously dispersed, andamplitude variation less than the standard value may indicate that thebatch ingredients are fully dissolved. As another example, when twostandard values are used, an amplitude variation greater than the firststandard value may indicate that the batch ingredients are notdissolved, an amplitude variation less than the first standard value butgreater than the second standard value may indicate that the batchingredients are homogeneously dispersed, and an amplitude variation lessthan the second standard value may indicate that the batch ingredientsare fully dissolved. The standard value may be the same for differentbatches of the same recipe. The standard value may be different fordifferent recipes.

In some embodiments, the method includes providing one or moreindications (e.g., a signal or an alert). The indication may correspondto the degree of inhomogeneity. The indication may be provided when theamplitude variation of the drive gain is within 15% (e.g., within 10%,5%, 2%, or 1%) of the standard value. For example, one indication maycorrespond to a batch with ingredients that are not dissolved; anotherindication may correspond to a batch with ingredients that arehomogeneously dispersed; and yet another indication may correspond to abatch with ingredients that are fully dissolved. In some embodiments, anindication is provided when the batch ingredients are fully dissolved.In some embodiments, an indication is provided when the batchingredients are homogeneously dispersed and another indication isprovided when the batch ingredients are fully dissolved.

In some embodiments, additional ingredients are added only after theindication indicates that the ingredients are homogeneously dispersed.In some embodiments, additional ingredients are added only after theindication indicates that the ingredients are fully dissolved. In someembodiments, whether additional ingredients are added after theindication indicates that the ingredients are homogeneously dispersed orthat the ingredients are fully dissolved depends on the characteristicsof the prior ingredient, and whether the batch recipe calls for theprior ingredient to be homogeneously dispersed or to be fully dissolvedbefore adding the next ingredient.

In some embodiments, software in communication with the in-line densitydevice may monitor the amplitude variation of the drive gain, comparethe amplitude variation of the drive gain, and provide the indicationbased on the amplitude variation.

It is also possible to use these processes on existing equipment byretrofitting the equipment with the in-line density device. For example,the in-line density device can be added to an existing productionprocess without requiring significant modifications or equipment downtime. An existing batch process or equipment for producing a beveragecan be modified by adding a recirculation loop with an in-line densitydevice to measure density and to an existing batch process. FIG. 1illustrates an exemplary system 50 with recirculation loop 90 andin-line density device 100 that could be added to retrofit and existingsystem. The following examples illustrate how this method can be used tomeasure density and homogeneity in a batch process for making abeverage. The examples show how the measurements are made, how themeasurements can be compared either to a standard recipe or to otherprocesses producing the same beverage. Additionally, the examples showthat this method can detect even slight changes in density orhomogeneity that may affect batch quality. These examples furtherillustrate that this method can produce measurement results with nearlythe same precision as a more complex, off-line density measurementapparatus and method.

EXAMPLE 1

One experiment tested the production of two different batches of syrup(“Batch 1” and “Batch 2”), beginning with about 40 gallons of water.Ingredients A, B, C, D, E, F, G, H, and I were added in sequence. Table1 shows the sequence and mass of ingredients added to Batch 1 and Batch2. So, for example, Ingredient A was added to the batch at two differenttimes, in a total amount of 266 grams, and Ingredient G was added toBatch 1 once and to Batch 2 twice, in a total amount of 144 grams foreach batch. FIG. 6 shows the density and drive gain of Batch 1 overtime. The left y-axis shows density (g/cm³), the right y-axis showsdrive gain, and the x-axis shows time (seconds). Line 300 represents thedensity of the batch over time, and line 400 represents drive gain overtime.

TABLE 1 Mass added Mass added to Batch 1 to Batch 2 Sequence Ingredient(grams) (grams) 1 Water 150969 150969 2 A 133 133 3 A 133 133 4 B 14 145 B 14 14 6 C 579 386 7 C 579 386 8 C 0 386 9 D 47 0 10 D 47 0 11 E 8484 12 E 84 84 13 F 236 236 14 F 236 236 15 G 144 72 16 G 0 72 17 H 130130 18 H 130 130 19 I 713 356 20 I 0 356

In this experiment, a Coriolis density meter (densitometer) wasincorporated in a recirculation loop mode to accurately track theaddition of ingredients and density changes during the batch process, inthe manner described above. The water was initially added to the mixingtank and the densitometer measured the water density. Each ingredientwas added in the form of solid powder. Once each ingredient was addedinto the mix, each ingredient passed through the meter and caused aspike in the density of the batch, shown by line 300 in FIG. 6, due tothe Coriolis effect. Each spike or sharp increase in density correspondsto the addition of the ingredient into the mix. Each spike is labeledwith a letter that corresponds to the ingredient that caused the spike.Once a well-dispersed mixture is present, the density reading levels offto steady-state (shown by the plateau regions between each spike in FIG.6). Moreover, the concentration of each ingredient was calculated basedon density measurements.

Additionally, the densitometer measured the drive gain of the batch. Thedrive gain, shown by line 400 in FIG. 6, indicates the presence ofmultiple phases in the batch. As shown in FIG. 6, the drive gain spikedat the time each ingredient was added to the batch, then decreased to ator near the original value. The decrease in drive gain following thespike indicates the solid powders have fully dissolved into the liquid.

As shown in FIG. 6, the drive gain increased following the addition ofIngredient G, then leveled off to a drive gain value higher than theoriginal. This is due to the fact that Ingredient G trapped air, whichaffected the density readings. Drive gain remained at a slightlyelevated level following the addition of Ingredient G, even after thebatch was fully mixed. Despite the elevated drive gain, it was stillpossible to detect changes in drive gain following the addition ofIngredient H and I.

During Batch 2 Ingredient D was not added, Ingredient C was added 3times (compared to 2 times in Batch 1), and Ingredients G and I wereeach added 2 times (compared to 1 time each in Batch 1). FIG. 7 showsthe density and drive gain of Batch 2 over time. The left y-axis showsdensity (g/cm³), the right y-axis shows drive gain, and the x-axis showstime (seconds). Line 300 represents the density of the batch over time,and line 400 shows drive gain over time.

FIG. 3 shows an expanded view of FIG. 7 at the times when Ingredient Cwas added during Batch 2, with line 300 representing density (g/cm³) andline 400 representing drive gain. As shown in FIG. 3, line 300 showsthree spikes, each corresponding to the addition of Ingredient C.Similarly, the drive gain spikes at each of those times. After theinitial spike for each addition of Ingredient C, line 300 reached asteady state at an increased density. Line 400 shows an increased drivegain following the addition of Ingredient C followed by a reduction backto the original drive gain from before Ingredient C was added. Thisindicated Ingredient C was initially undissolved in the batch, and aftera short time became fully dissolved in the liquid. As discussed relativeto Example 1, FIG. 7 shows a similar increase in drive gain during Batch2 following the addition of Ingredient G.

In addition to Ingredient A-I, following the addition of Ingredient I toBatch 2, gas was added to the batch to test the density and drive gainmeasurement. The addition of gas (labeled “J” in FIG. 7) caused anoticeable spike in drive gain and a sharp decrease in density.

FIG. 8 shows an expanded view of FIG. 7 at the times when Ingredient Bwas added, with line 300 representing density (g/cm³). Ingredient Bmakes up less than 0.02% of the total mass of the batch, but FIG. 8illustrates that it is possible to detect minor changes in densitycaused by the addition of a very small mass of ingredients. FIG. 8 showstwo peaks, labeled “B,” that correspond to the two stages of addition ofIngredient B to the batch.

The measurement results of Batch 1 and Batch 2 can be used to illustratehow the densitometer can be used to establish a standardized densitychart that represents target recipe data and ensure quality ofsubsequent batches. FIG. 9 shows a comparison of the densities in Batch1 and Batch 2. The y-axis shows density (g/cm³). Each bar represents thedensity of the batch after an ingredient has been added. For example, inBatch 1, Ingredient C was added in two stages, so bars 6 and 7 eachcorrespond to an addition of Ingredient C.

FIG. 9 shows the same density at points where the ingredient additionsequence of Batch 1 matches Batch 2, but shows deviations in densitywhen the addition sequence differed between Batch 1 and Batch 2. Forexample, the same amount of Ingredient C was added to both Batch 1 andBatch 2, but Ingredient C was added in two stages in Batch 1 and threestages in Batch 2. Because of the difference in addition sequence, thedensity at 7 is lower for Batch 2 than Batch 1 because not all ofIngredient C had been added to Batch 2. Comparing Batch 1 to Batch 2,differences between the batches can be readily determined. So, if Batch1 was the standardized recipe, looking at FIG. 9, it could be readilydetermined when and by how much Batch 2 deviated from the standard.

EXAMPLE 2

In another experiment, offline density measurements were taken of Batch2 using an offline density measurement instrument, and the results ofthe offline density measurements were compared to the in-line densitymeasurements.

The in-line density device used to measure density for Batch 1 and Batch2 had a density accuracy of ±0.1 kg/m³ (±0.0001 g/cm³) and a densityrepeatability of ±0.02 kg/m³ (±0.00002 g/cm³). For offline densitymeasurements, an Anton Paar DMA 5000M was used. The device had a densityaccuracy of ±0.005 kg/m³ (±0.000005 g/cm³), a density repeatability of±0.001 kg/m³ (0.000001 g/cm³).

FIG. 10 graphically shows the comparison of in-line density measurementsto offline density measurements. FIG. 10 shows concentration (% massingredient) on the y-axis and density (g/cm³) on the x-axis. As shown inFIG. 10, the in-line density measurements were similar, and nearlyidentical to, the offline density measurements, indicating the in-linedensity measurement method is at least as effective as offline densitymethods. FIG. 11 illustrates the difference between in-line densitymeasurements and offline density measurements of Batch 2. As shown inFIG. 11, the y-axis shows density (g/cm³) and the x-axis shows massconcentration. The data points shown in FIG. 11 represent the differencebetween the measurements of the in-line density device and the offlinedensity device. FIG. 11 illustrates that the in-line density devicemeasurements have very little error.

EXAMPLE 3

In another experiment, the in-line density device was used to measuredensity and drive gain for a batch process. Using the drive gainmeasurements, the amplitude variation of the drive gain was measured.Amplitude variation of the drive gain was determined based on themeasured drive gain. The amplitude variation of the drive gain was thenstatistically analyzed to show that drive gain amplitude variation canbe measured to differentiate between a fully dissolved mixture and ahomogeneously dispersed mixture. FIG. 12 shows the results of thestatistical analysis of the drive gain amplitude for various samples.Table 2 shows the composition of each sample that passed through thein-line density device.

TABLE 2 Sample Composition A Water only B Liquid (e.g., flavors,acidulents, etc.) dissolved in water C Powder homogeneously dispersed,but not dissolved, in water D Liquid and powder dissolved in water withsystem perturbations (e.g., pressure change, air bubbles, etc.) E Liquidand powder dissolved in water with no system perturbations F Powderdissolved in water

For each of samples A, B, C, D, E, and F, drive gain amplitude variationwas measured using the densitometer. The confidence intervals of eachset of measured data are illustrated in FIG. 12. Confidence intervalsfor samples A, B, C, D, E, and F are represented in FIG. 12 by lines500, 501, 502, 503, 504, and 505, respectively.

Further, FIG. 13 shows boxplots illustrating the drive gain of each ofsamples A, B, C, D, E, and F. Boxplots for samples A, B, C, D, E, and Fare represented in FIG. 12 by 600, 601, 602, 603, 604, and 605,respectively. The x-axis shows values for drive gain. Each box shows themiddle 50% of drive gain data points for each sample. A wider box (e.g.,sample C) indicates that the drive gain data points were more widelyspread out than other groups. A larger spread of drive gain correspondsto a higher drive gain amplitude variation.

The drive gain amplitude variations are significantly different fromeach other if their confidence intervals shown in FIG. 12 do notoverlap. For example, the confidence intervals of samples B and Foverlap, but all other samples are significantly different from eachother. Overall p-value is near 0 based on Levene's Test, which is lessthan 5%. This statistical analysis shows that the drive gain amplitudevariations can be used to detect variations in the condition of thebatch or mixture.

Further, as can be seen in FIG. 13, the lowest drive gain amplitudevariation occurs with only one component (e.g., sample A (600)). Incontrast, the highest drive gain amplitude variation exists with SampleC (602), which included fine powders added to water that were dispersedbut not dissolved. The drive gain amplitude variation is similar forboth liquid dissolved in water (e.g., sample B (601)) and powderdissolved in water (e.g., sample F (605)). This indicates that thesystem behavior is similar once the ingredient is fully dissolved,regardless whether the ingredient is a liquid or solid.

As shown by the relatively smaller box 604 compared to box 603, thewell-mixed, homogeneously dissolved sample (e.g., sample E (604)) withno system perturbations has less drive gain amplitude variation than thesame sample but with system perturbations (e.g., sample D (603)).External perturbations may include, for example, pressure changes, airbubbles, variations in pump speed, system vibrations, flow rate changes,etc. Without being bound by theories, sample E shows less variationbecause the homogeneous dissolution creates a pseudo single-phasemixture with drive gain amplitude variations more similar to sample A.As shown by comparing sample E (no perturbations) with sample D (withperturbations), external system perturbations can cause an increase indrive gain amplitude variation.

Accordingly, as illustrated in Example 3, amplitude variation of drivegain can be used to distinguish between a homogeneously dispersedmixture (e.g., sample C) and a fully dissolved mixture (e.g., samples B,D, E, and F).

As used herein, the term “fully mixed” or “well-mixed” means the batchhas been mixed so that the ingredients have dissolved or mixed into thebatch such that all of the components in the mixture are fullydispersed. For example, if a solid powder is added to the batch, thebatch will be “fully mixed” or “well-mixed” when the powder is no longervisible in the batch. Additionally, the batch may be “fully mixed” or“well-mixed” if the fluctuations in density (e.g., as measured by thedensitometer) are less than or equal to ±5%.

The principles of this disclosure related to, for example, trackingingredients, monitoring batch quality, and determining degree ofhomogeneity or dissolution can be applied to applications beyondbeverage production. For example, these principles may be used inapplications in other industries, including pharmaceuticals, home andpersonal care, chemicals, and oil and gas.

As used herein, the term “homogeneously dispersed” means that thecomponents that make up the mixture are uniformly dispersed throughoutthe mixture, but may or may not be fully dissolved.

As used herein, the term “fully dissolved” or “homogeneously dissolved”means that all ingredients (e.g., solids, liquids, or gases) in thebatch have dissolved in the batch.

It is to be appreciated that the Detailed Description section, and notthe Summary and Abstract sections, is intended to be used to interpretthe claims. The Summary and Abstract sections may set forth one or morebut not all exemplary embodiments of the present invention ascontemplated by the inventor(s), and thus, are not intended to limit thepresent invention and the appended claims in any way.

The present invention has been described above with the aid offunctional building blocks illustrating the implementation of specifiedfunctions and relationships thereof. The boundaries of these functionalbuilding blocks have been arbitrarily defined herein for the convenienceof the description. Alternate boundaries can be defined so long as thespecified functions and relationships thereof are appropriatelyperformed.

The foregoing description of the specific embodiments will so fullyreveal the general nature of the invention that others can, by applyingknowledge within the skill of the art, readily modify and/or adapt forvarious applications such specific embodiments, without undueexperimentation, without departing from the general concept of thepresent invention. Therefore, such adaptations and modifications areintended to be within the meaning and range of equivalents of thedisclosed embodiments, based on the teaching and guidance presentedherein. It is to be understood that the phraseology or terminologyherein is for the purpose of description and not of limitation, suchthat the terminology or phraseology of the present specification is tobe interpreted by the skilled artisan in light of the teachings andguidance.

The breadth and scope of the present invention should not be limited byany of the above-described exemplary embodiments, but should be definedonly in accordance with the claims and their equivalents.

What is claimed is:
 1. A method of producing a beverage according to abatch process, comprising: adding a first ingredient to water to form abatch; mixing the batch; measuring a drive gain of the batch using anin-line density device; monitoring amplitude variation of the drivegain; comparing the amplitude variation of the drive gain to apredetermined threshold; and providing an indication that the batch iseither homogeneously dispersed or fully dissolved based on thecomparison of the amplitude variation of the drive gain to thepredetermined threshold, wherein the mixing continues until theindication is provided.
 2. The method of claim 1, further comprising:adding a second ingredient to the batch; adding a third ingredient tothe batch; and repeating the mixing, measuring, monitoring, comparing,and providing steps after addition of each of the second and thirdingredients.
 3. The method of claim 1, wherein the comparing stepfurther comprises: determining whether the amplitude variation of thedrive gain is greater than or less than the predetermined threshold. 4.The method of claim 3, wherein the indication is provided when theamplitude variation of the drive gain is less than the predeterminedthreshold.
 5. The method of claim 1, further comprising: determiningwhether the amplitude variation of the drive gain is less than apredetermined threshold.
 6. The method of claim 5, wherein theindication indicates that the batch is fully dissolved, and wherein themethod further comprises: adding a second ingredient to the batch afterthe indication is provided.
 7. The method of claim 1, wherein theamplitude variation of the drive gain is measured continuously.
 8. Themethod of claim 1, wherein the measuring step, monitoring step, andcomparing step are performed by software in communication with thein-line density device.
 9. The method of claim 8, wherein the softwareprovides an automatic alert if the comparing step determines that thevariation in drive gain amplitude is less than the predeterminedthreshold.
 10. The method of claim 9, further comprising adding a secondingredient to the batch after the software provides the automatic alert;and repeating the mixing step.
 11. The method of claim 1, wherein thepredetermined threshold is within 10% of a target variation in drivegain amplitude.
 12. The method of claim 1, wherein the drive is measuredin real time.
 13. A method for detecting homogeneity or dissolution ofingredients of a mixture, comprising: measuring a drive gain amplitudeof a mixture using an in-line density device, the mixture comprising aliquid and at least one additional ingredient; monitoring amplitudevariation of the drive gain; comparing the amplitude variation of thedrive gain to a predetermined threshold; and determining, whether themixture is fully dissolved or is homogeneously dispersed based on thecomparison of the amplitude variation of the drive gain to thepredetermined threshold.
 14. The method of claim 13, wherein the atleast one additional ingredient comprises at least two additionalingredients, and wherein the method further comprises mixing the mixturecomprising the at least two additional ingredients while measuring thedrive gain amplitude.
 15. The method of claim 13, further comprising:adding at least one second additional ingredient after the determiningstep; and repeating the measuring, monitoring, comparing, anddetermining steps after adding the at least one second additionalingredient.
 16. The method of claim 13, wherein the measuring isperformed continuously.
 17. The method of claim 13, further comprisingproviding an indication when the determining step determines that themixture is fully dissolved.
 18. The method of claim 17, furthercomprising mixing the batch continuously until the indication indicatesthat the mixture is fully dissolved.
 19. A method for detecting degreeof dissolution of a mixture, comprising: adding a first ingredient towater to form a batch; mixing the batch; measuring a drive gainamplitude of the batch in real time using an in-line density device;monitoring amplitude variation of the drive gain; comparing theamplitude variation to a first standard reference and a second standardreference, wherein the first standard reference corresponds to ahomogeneously dispersed mixture, and wherein the second standardreference corresponds to a fully dissolved mixture; and providing anindication of the degree of mixing based on the comparing step.
 20. Themethod of claim 19, wherein the indication is provided when theamplitude variation is within 10% of the first standard reference. 21.The method of claim 20, further comprising providing a second indicationof the degree of mixing when the amplitude variation is within 10% ofthe second standard reference.
 22. The method of claim 19, furthercomprising adding a second ingredient to the batch when the indicationindicates that the batch is fully dissolved.
 23. The method of claim 22,further comprising repeating the mixing, measuring, monitoring, andcomparing, and providing steps after the second ingredient is added.